CN111859483B - Lightweight design method for armor type thin-wall structure - Google Patents
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Abstract
The invention discloses an armor type thin-wall structure lightweight design method, which belongs to the field of aerospace equipment and comprises the following steps: based on the initial structure design of the internal pressure bearing part, covering a layer of thin-wall structure with uniform thickness on the surface of the thinned region of the geometric model with the thinned thickness to obtain a geometric model to be optimized; carrying out grid division by adopting a second-order or high-order entity unit, and applying a boundary constraint condition and a load condition to obtain a finite element analysis model; obtaining an optimal material distribution within a design domain; establishing a parameterized solid geometric model of the internal pressure bearing part after topology optimization; obtaining optimal parameter optimization design variable values, and finally obtaining an armor type thin-wall structure lightweight design model of the designed object part; the method completely comprises a concept design stage and a detailed design stage, and simultaneously provides a geometric model processing method required by topology optimization and a parameterized geometric model modeling method required by parameter optimization, and the methods have good operability and convenience.
Description
Technical Field
The invention relates to the field of aerospace equipment, in particular to a lightweight design method for an armor type thin-wall structure.
Background
The thin-wall structure under the action of the internal pressure load is widely applied to various engineering fields such as aerospace, chemical machinery and the like, such as a conveying pipeline, an engine air inlet and the like. In the related art, some devices have high requirements for the lightweight degree of the structure. For a long time, the light weight of the thin-wall structure is mostly realized by adopting a mode of reinforcing rib design instead of uniform thickness design. This is because, under the same material usage, the reinforced configuration has better bending resistance, thereby effectively utilizing the mechanical properties of the material. By introducing a structural parameter optimization technology, the optimized design is carried out on the rib layout, and the material utilization efficiency can be further improved. However, whatever the reinforcement method, the ribs are required to have sufficient height and to be continuously distributed, which results in several disadvantages of the reinforcement configuration:
1) High quality manufacturing presents difficulties. Since the rib thickness is significantly greater than the thin-walled region, it is economical to weld the rib to the surface of the thin-walled structure, which is prone to processing defects. For this reason, the processing method is less adopted for equipment with high reliability requirements, such as aircraft engines and the like. Secondly, in order to adopt a chemical milling processing mode, but the precision and controllability of the processing mode are limited, the weight of the obtained actual product is often larger than the design weight, and the estimation of the total weight and the mass center of the equipment is influenced. The highest precision processing mode is that a reinforced thin-wall structure is milled step by step from a whole block of material by adopting numerical control processing, but the processing process is very time-consuming, and meanwhile, materials are greatly wasted.
2) Some ribs are inefficient. Since most of the ribs are arranged continuously, i.e. continuously extending from one end of the structure to the other or end-to-end with itself, the areas where no material needs to be added are also added with material, and thus the weight of the structure is not reduced most effectively.
3) Under the action of the thermal combined load, the phenomenon of high stress is easy to occur. In the fields of aerospace, chemical machinery and the like, a plurality of thin-wall components bear the effects of internal pressure load and temperature load at the same time. Since the rate of temperature change is directly related to the thickness of the thin-walled region, the rib height in the stiffened design often needs to be significantly higher than the thin-walled region. Therefore, in the process of heating or cooling, the root of the rib is easy to generate a larger stress concentration phenomenon, so that the service life of the structure is shortened, and even the structure is damaged.
In order to overcome the defects existing in the reinforcement design, the patent provides a novel structural design structure which can be used for the light weight of the internal pressure-bearing thin-wall structure. It is referred to as an armor-type thin-walled structural design because its structural design features are similar to those of a structure that is jacketed at the weak points with a layer of armor. The arrangement area and the shape of the armor are obtained by a structural optimization design process covering a conceptual design stage and a detailed design stage. Wherein the conceptual design stage will use topology optimization techniques and the detailed design stage will use parameter optimization techniques (including shape optimization and parameter optimization).
Disclosure of Invention
According to the problems in the prior art, the invention discloses an armor type thin-wall structure lightweight design method, which comprises the following steps:
s1: based on the initial structure design of the internal pressure bearing component, thinning the thin-wall area of the internal pressure bearing component to obtain a geometric model with the thinned thickness;
s2: modeling through a geometric model, covering a layer of thin-wall structure with uniform thickness on the surface of the thinned region of the geometric model with the thinned thickness to obtain a geometric model to be optimized, and defining the generated thin-wall structure with uniform thickness as a design domain;
s3: carrying out grid division on a geometric model to be optimized by adopting a second-order or high-order entity unit, and applying a boundary constraint condition and a load condition to obtain a finite element analysis model;
s4: the method comprises the steps of establishing a topological optimization column of an internal pressure bearing part by taking the volume of a reserved material smaller than a set value as a constraint condition and maximizing structural rigidity under an internal pressure load or under the combined load of internal pressure and temperature as a target function, and performing topological optimization on material distribution in a design domain based on an established finite element analysis model to obtain optimal material distribution in the design domain;
s5: establishing a parameterized solid geometric model of the internal pressure bearing part after topological optimization based on the optimal material distribution in the design domain;
s6: carrying out sensitivity analysis on design parameters of the parameterized entity geometric model, and determining a plurality of parameters as design variables for parameter optimization;
s7: and taking the stress peak value or the structural fundamental frequency to meet the structural design requirement as a constraint condition, taking the structural weight minimization as a target function, carrying out parameter optimization to obtain an optimal parameter optimization design variable value, and finally obtaining the armor type thin-wall structure lightweight design model of the designed object part.
Further, the armor thin-walled structure is characterized as follows: has two areas of different thickness, the junctions of the different thicknesses being transited by chamfers or fillets.
Further, the armor thin-walled structure design requirements are as follows: in the topology optimization, the optimal distribution of materials is obtained by taking the maximum rigidity as a target and taking the material consumption lower than a set value as a constraint condition; in parameter optimization, the stress peak value is lower than a set value or the fundamental frequency is higher than the set value as a constraint condition, and the aim of minimizing the material consumption is to obtain the final lightweight design of the armor type thin-wall structure.
Furthermore, the process of reducing the thickness of the thin-wall area of the internal pressure bearing component requires that the inner surface of the thin-wall area is kept unchanged and the thickness reduction is only carried out on the outer surface of the thin-wall area; in the final lightweight design of the armor type thin-wall structure, the inner surface of the thin-wall structure is the same as the initial design of the internal pressure bearing part, and the outer surface is different.
Further, the modeling method of the parameterized solid geometric model comprises the following steps:
s5-1: based on the optimal material distribution in the design domain obtained by topological optimization, selecting a plurality of points as boundary points on the boundaries of all the optimized reserved regions;
s5-2: establishing a parameterized spline curve by taking the selected boundary points as control points, wherein the parameters of the parameterized spline curve are the position coordinates of each control point;
s5-3: based on the generated spline curve, cutting the generated geometric model of the design domain, and deleting the non-reserved region;
s6-4: and fusing the finite element analysis model and the geometric model to be optimized into a geometric model by adopting Boolean operation, and adding chamfers or fillets to the thickness mutation positions after fusion to obtain the parameterized entity geometric model for parameter optimization.
Due to the adoption of the technical scheme, the invention provides the lightweight design method of the armor type thin-wall structure, the armor type thin-wall structure is provided with 2 thin-wall regions with different thicknesses, the structure is simple in structure and easy to process, the number of materials to be cut is small, the material preparation volume can be reduced, the time consumption of numerical control processing can be reduced, and the structure with low reliability requirement can be processed and manufactured in a more economic veneer pasting mode; the positions or the distribution of the 2 thin-wall regions with different thicknesses depend on a structure optimization design technology, so that the mechanical property of the material can be reasonably utilized, and a structural design with higher light weight degree is obtained; the joint of the thin-wall areas with different thicknesses is transited by a chamfer or a fillet, so that large thickness gradient change does not exist, the stress peak value in the structure in the heating or cooling process is favorably inhibited, and the service life of the structure is prolonged; the design process completely comprises a concept design stage and a detailed design stage, and simultaneously provides a geometric model processing method required by topology optimization and a parameterized geometric model modeling method required by parameter optimization, and the methods have good operability and convenience.
Drawings
In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the description below are only some embodiments described in the present application, and other drawings can be obtained by those skilled in the art without creative efforts.
FIG. 1 is a flow chart of an embodiment of the present invention;
FIG. 2 is an initial structural layout of an embodiment of the present invention;
FIG. 3 is a diagram of a dual layer structure according to an embodiment of the present invention;
FIG. 4 is a partial view of a bilayer configuration according to an embodiment of the present invention;
FIG. 5 is a diagram of a grid model according to an embodiment of the present invention;
FIG. 6 is a graph of applied load versus boundary conditions for an embodiment of the present invention;
FIG. 7 is a graph of material distribution retained after topology optimization according to an embodiment of the invention;
FIG. 8 is a dot plot of the boundary of the retained material region according to an embodiment of the present invention;
FIG. 9 is a graph illustrating spline construction according to an embodiment of the present invention;
FIG. 10 is a geometric model of a retained material according to an embodiment of the present invention;
FIG. 11 is a diagram of an addition of an inner layer structure and a reserved structure according to an embodiment of the present invention;
FIG. 12 is a geometric model of a symmetrical and chamfered embodiment of the present invention.
Detailed Description
In order to make the technical solutions and advantages of the present invention clearer, the following describes the technical solutions in the embodiments of the present invention clearly and completely with reference to the drawings in the embodiments of the present invention:
the armor type thin-wall structure is characterized as follows: (1) The designable thin-wall area in the armor type thin-wall structure is combined by 2 areas with different thicknesses, the distribution and the shape of the areas with different thicknesses are obtained by corresponding optimized design processes, and the mechanical properties of materials can be reasonably utilized, so that the light weight of the structure is effectively realized; (2) The structure optimization design process has good integrity, covers a concept design stage and a detailed design stage, and introduces an applicable structure optimization design technology in both the two stages, thereby ensuring that more effective lightweight design is obtained; (3) The areas with different thicknesses are transited by chamfers or fillets, so that the thickness change of the material is smooth, and the high stress phenomenon caused by temperature load is reduced more favorably than the reinforced design.
FIG. 1 illustrates a flow diagram of an embodiment of the present invention; an armor type thin-wall structure lightweight design method comprises the following steps:
s1: determining a thin-wall region which can be changed in design of an internal pressure bearing component based on an initial structure design (fig. 2 is an initial structure design diagram of the embodiment of the invention), then reducing the structural thickness of the region, wherein a specific reduction thickness value depends on design requirements or processing requirements, and needs to be determined based on early trial calculation or experience of designers, the position of an inner surface, namely an internal pressure acting surface, of the thin-wall structure design is required to be kept unchanged, and only the position of an outer surface is required to be changed, so that a geometric model after the thickness reduction is obtained;
wherein: the thin-wall component bearing the internal pressure effect is widely applied to the fields of aerospace, chemical engineering and the like, for example, a pipeline for conveying substances or a high-pressure compressor casing of an aeroengine, the internal pressure load effect caused by internal high-pressure fluid or gas can be borne by the internal part of the thin-wall component due to functional requirements, the internal shape of the thin-wall component is often limited by the functional requirements and cannot be changed at will, and the external appearance of the thin-wall component can be changed.
S2: modeling through a geometric model, covering a layer of thin-wall structure with uniform thickness on the surface of a thinned region of the geometric model after the thickness is thinned, determining to obtain the geometric model to be optimized according to the design or processing requirement of the thickness value, and taking the generated thin-wall structure with uniform thickness as a design domain;
FIG. 3 is a diagram of a dual layer structure according to an embodiment of the present invention; FIG. 4 is a partial view of a bilayer configuration according to an embodiment of the present invention;
the geometric model generated in the step S1 after the thickness reduction is a non-design domain. When the experience of the design object is insufficient, multiple trial calculation works are needed in the early stage of design, and the thickness values in the steps S1 and S2 are determined according to the comparison between the calculation results under different thicknesses and the design requirements;
s3: a geometric model to be optimized needs to adopt second-order or high-order entity units to divide grids, and fig. 5 is a grid model diagram in the embodiment of the invention; and applying constraint conditions and load conditions according to actual conditions to obtain a finite element analysis model, wherein the load can comprise internal pressure load and temperature load, fig. 6 is a graph of applied load and boundary conditions of the embodiment of the invention, and the grids of a joint surface of a design domain and a non-design domain need to be ensured to be superposed when the grids are divided, which is beneficial to reducing the interference of numerical errors.
The reason for adopting the second-order or high-order entity units is that when the first-order entity units are adopted, in order to ensure the numerical analysis precision, at least two layers of finite element units need to be divided in the thickness direction of the thin-wall structure, but the thickness dimension of the thin-wall structure is far smaller than the dimensions in the other two directions, and the quality control criterion of the entity units requires that the ratio of the dimensions in different directions of each unit cannot be too large, so that the grid scale of the optimization analysis model is too large by adopting the first-order entity unit division design domain. For the classical topology optimization theory, the number of design variables is the number of elements in the design domain. Therefore, if the first-order solid elements are adopted, on one hand, the difficulty of finite element model division is increased, and on the other hand, the number of design variables is too large, so that the details of an optimization result are too large, and the difficulty of modeling the parameterized geometric model is increased. If the secondary unit is adopted, when the requirement on analysis precision is not high, only one layer of unit can be arranged in the thickness direction, so that the modeling difficulty of the finite element model can be reduced, the number of design variables can be reduced, and a relatively simple topological optimization result can be obtained, thereby providing convenience for modeling the parameterized geometric model.
S4: and establishing a topological optimization column of the internal pressure-bearing part by taking the reserved material volume as a constraint condition and carrying out topological optimization on the material distribution in a design domain based on the established finite element analysis model to obtain the optimal material distribution. Because the thin-wall structure usually bears internal pressure, external pressure or axial pressure load, the rigidity of the structure is one of the most common structural performance indexes, and meanwhile, the topological optimization design with the structural rigidity maximized as the target is the structural optimization design method in the most mature and robust conceptual design stage. Therefore, the design process of the patent firstly carries out conceptual design on material distribution by using rigidity maximization topological optimization, namely rigidity maximization topological optimization design, also called minimum flexibility topological optimization, and the optimization column is
find ρ＝{ρ 1 ,ρ 2 ,......,ρ N } (1)
min C＝F T U (2)
s.t.KU＝F (3)
Where ρ is a design variable vector, ρ i The artificial density of the ith unit, N the number of all units in the design domain, K, U and F are respectively a structural rigidity array, a displacement vector and an external loadVector, V i e Is the volume of the ith cell and,
η is the upper limit of the volume fraction set for the design domain volume. FIG. 7 is a graph of material distribution retained after topology optimization according to an embodiment of the invention; the size of the reserved area depends on the value of eta in the constraint condition.
S5: and establishing a geometric model of the parameters of the internal pressure bearing component after topological optimization based on the optimal material distribution in the design domain. The modeling method of the parameterized solid geometric model comprises the following steps:
s5-1, selecting a plurality of points of the boundary of the reserved area, selecting enough boundary points for describing the shape of the boundary, and obtaining the spatial positions of the points, wherein a point diagram of the boundary of the reserved material area is shown in FIG. 8;
s5-2, establishing a parameterized spline curve by taking the selected boundary points as control points, wherein the parameters of the parameterized spline curve are the position coordinates of each control point; FIG. 9 is a spline graph constructed in accordance with an embodiment of the present invention;
s5-3, based on the generated spline curve, cutting the generated geometric model of the design domain, and deleting the non-reserved area to obtain the geometric model of the reserved material, wherein FIG. 10 is a geometric model diagram of the reserved material according to the embodiment of the invention;
s5-4, fusing a finite element analysis model and a geometric model to be optimized into a solid geometric model by adopting Boolean operation, wherein FIG. 11 is an added graph of an inner layer structure and a reserved structure in the embodiment of the invention; because of the symmetry of the example model, the quarter model is firstly modeled during modeling, a geometric model of a complete structure is obtained through symmetry, and chamfers are added at the positions of thickness steps, fig. 12 is a geometric model diagram which is symmetrical and added with chamfers according to the embodiment of the invention, and the modeling work can be realized by adopting most commercial or open-source geometric modeling software.
S5-5: selecting a plurality of parameters as design variables, taking the performance requirements of the thin-wall structure as constraint conditions, such as the stress peak value is lower than a set value, the maximum deformation is lower than the set value or the fundamental frequency is higher than the set value, and the like, and developing the optimized design of the shape parameters or the chamfering parameters of the thickened region by taking the structure weight minimization as an objective function.
The parameter optimization is widely applied to the fields of mechanical design and the like. Therefore, the tools which can be used for optimizing the parameters are abundant, and the CAE commercial software with built-in parameter optimization functions such as Ansys and Abaqus and the special parameter optimization platform such as Isight are available. The difficulty of the parameter optimization implementation lies in the establishment of a reasonable parameterized model, and the optimization process proposed by the patent can achieve the goal. Under the optimization process of the patent, the design parameters in the parameter optimization design stage are position parameters of spline curve control points for controlling thickness distribution. The control point of the Spline curve may be a position at which a use point of the Spline curve is generated, or may be a control point position parameter corresponding to the constructed Spline curve. The optimization tool recommends the use of an Ansys Workbench platform, so that the optimization capability of the spline curve control point position parameter is better. The optimization formula of the optimization problem is as follows,
Find x i ，y i ，z i i＝1,2,..,N (5)
min V (6)
wherein x is i ，y i ，z i Is the X-axis, Y-axis and Z-axis coordinates of the ith control point, V is the total volume of the structure, g j Is the jth inequality constraint, f k For the kth equality constraint, N, L and M are respectively the number of control points, the number of inequality constraints and the number of equality constraints to be optimized.
The above description is only for the preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art should be considered as the technical solutions and the inventive concepts of the present invention within the technical scope of the present invention.
Claims (5)
1. An armor type thin-wall structure lightweight design method is characterized by comprising the following steps:
s1: based on the initial structure design of the internal pressure bearing component, thinning the thin-wall area of the internal pressure bearing component to obtain a geometric model with thinned thickness;
s2: modeling through a geometric model, covering a layer of thin-wall structure with uniform thickness on the surface of a thinned region of the geometric model with the thinned thickness to obtain the geometric model to be optimized, and defining the generated thin-wall structure with uniform thickness as a design domain;
s3: carrying out grid division on a geometric model to be optimized by adopting a second-order or high-order entity unit, and applying a boundary constraint condition and a load condition to obtain a finite element analysis model;
s4: the method comprises the steps of establishing a topological optimization column of an internal pressure-bearing component by taking the volume of a reserved material smaller than a set value as a constraint condition and maximizing structural rigidity under an internal pressure load or under the combined load of internal pressure and temperature as an objective function, and carrying out topological optimization on material distribution in a design domain based on an established finite element analysis model to obtain optimal material distribution in the design domain;
s5: establishing a parameterized solid geometric model of the internal pressure bearing part after topological optimization based on the optimal material distribution in the design domain;
s6: carrying out sensitivity analysis on design parameters of the parameterized entity geometric model, and determining a plurality of parameters as design variables for parameter optimization;
s7: and (3) carrying out parameter optimization by taking the stress peak value or the structural fundamental frequency as constraint conditions and taking the structure weight minimization as a target function so as to obtain an optimal parameter optimization design variable value, and finally obtaining an armor type thin-wall structure lightweight design model of the designed object part.
2. The armor type thin-wall structure lightweight design method according to claim 1, further characterized by: the armor thin-walled structure is characterized as follows: there are two areas of different thickness, the junctions of the different thicknesses being transited by chamfers or fillets.
3. The armor type thin-wall structure lightweight design method according to claim 1, further characterized by: the armor type thin-wall structure has the following design requirements: in the topology optimization, the optimal distribution of materials is obtained by taking the maximum rigidity as a target and taking the material consumption lower than a set value as a constraint condition; in parameter optimization, the stress peak value is lower than a set value or the fundamental frequency is higher than the set value as a constraint condition, and the aim of minimizing the material consumption is to obtain the final lightweight design of the armor type thin-wall structure.
4. The armor type thin-wall structure lightweight design method according to claim 1, further characterized by: the process of thinning the thin-wall area of the internal pressure bearing component requires that the inner surface of the thin-wall area is kept unchanged and the thickness of the thin-wall area is thinned only on the outer surface of the thin-wall area; in the final lightweight design of the armor type thin-wall structure, the inner surface of the thin-wall structure is the same as the initial design of the internal pressure bearing part, and the outer surface is different.
5. The armor type thin-wall structure lightweight design method according to claim 1, further characterized by: the modeling method of the parameterized solid geometric model comprises the following steps:
s5-1: based on the optimal material distribution in the design domain obtained by topological optimization, selecting a plurality of points as boundary points on the boundaries of all the optimized reserved regions;
s5-2: establishing a parameterized spline curve by taking the selected boundary points as control points, wherein the parameter of the parameterized spline curve is the position coordinate of each control point;
s5-3: based on the generated spline curve, cutting the generated geometric model of the design domain, and deleting the non-reserved region;
s6-4: and fusing the finite element analysis model and the geometric model to be optimized into a geometric model by adopting Boolean operation, and adding chamfers or fillets to the positions of thickness mutation after fusion to obtain the parameterized entity geometric model for parameter optimization.
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